Polycrystalline diamond compact table with polycrystalline diamond extensions therefrom

ABSTRACT

A polycrystalline element includes a table formed of polycrystalline diamond. The table includes a first surface; a second surface spaced apart from the first surface; and at least one side extending between the first surface and the second surface. The table also includes a plurality of extensions also formed of polycrystalline diamond, wherein at least one extension of the plurality of extensions extends away from at least one of the first surface and the at least one side. The at least one extension of the plurality of extensions includes a first portion that is polyhedral shaped. Optionally, the polycrystalline diamond of at least one extension of the plurality of extensions is contiguous with the polycrystalline diamond of the table. The polycrystalline element may be used in downhole tools for boring and well drilling, machine tools, and bearings.

PRIORITY CLAIM

This application is a divisional application of U.S. patent applicationSer. No. 16/516,990 entitled “Polycrystalline Diamond Compact Table WithPolycrystalline Diamond Extensions Therefrom” filed on Jul. 19, 2019,which in turn claims the benefit of and priority to Chinese PatentApplication No. 201910619927.6 entitled “Polycrystalline Diamond CompactTable With Polycrystalline Diamond Extensions Therefrom” filed on Jul.10, 2019, which are incorporated in their entirety for all purposes bythis reference.

FIELD

The present application relates to polycrystalline elements that includea table formed of polycrystalline diamond. The table also includes aplurality of extensions also formed of polycrystalline diamond, whereinat least one extension of the plurality of extensions extends away fromat least one of the first surface and the at least one side. Thepolycrystalline element may be used in downhole tools for boring andwell drilling of water wells; oil and gas wells; injection wells;geothermal wells; monitoring wells, mining; and, other operations inwhich a well-bore is drilled into the Earth. The polycrystallineelements may also be used in machine tools and bearings.

BACKGROUND

Specialized drill bits and other downhole tools are used to drillwell-bores, boreholes, or wells in the earth for a variety of purposes,including water wells; oil and gas wells; injection wells; geothermalwells; monitoring wells, mining; and, other similar operations.Referring specifically to drill bits, the bits come in two common types,roller cone drill bits and fixed cutter drill bits.

Wells and other holes in the earth are drilled by attaching orconnecting a drill bit to some structure or method of turning the drillbit. In some instances, such as in some mining applications, the drillbit is attached directly to a shaft that is turned by a motor, engine,drive, or other source of torque capable of rotating the drill bit.

In other applications, such as oil and gas drilling, the well may beseveral thousand feet or more in total depth. In these circumstances,the drill bit is connected to the surface of the earth by what isreferred to as a drill string and a motor or drive that rotates thedrill bit. The drill string typically comprises several elements thatmay include a special down-hole motor configured to provide additionalor, if a surface motor or drive is not provided, the only means ofturning the drill bit. Special logging and directional tools to measurevarious physical characteristics of the geological formation beingdrilled and to measure the location of the drill bit and drill stringmay be employed. Additional drill collars, heavy, thick-walled pipe,typically provide weight that is used to push the drill bit into theformation. Finally, drill pipe connects these elements, the drill bit,down-hole motor, logging tools, and drill collars, to the surface wherea motor or drive mechanism turns the entire drill string and,consequently, the drill bit, to engage the drill bit with the geologicalformation to drill the well-bore deeper.

As a well is drilled, fluid, typically a water or oil based fluidreferred to as drilling mud is pumped down the drill string through thedrill pipe and any other elements present and through the drill bit.Other types of drilling fluids are sometimes used, including air,nitrogen, foams, mists, and other combinations of gases, but forpurposes of this application drilling fluid and/or drilling mud refersto any type of drilling fluid, including gases. In other words, drillbits typically have a fluid channel within the drill bit to allow thedrilling mud to pass through the bit and out one or more jets, ports, ornozzles. The purpose of the drilling fluid is to cool and lubricate thedrill bit, stabilize the well-bore from collapsing or allowing fluidspresent in the geological formation from entering the well-bore, and tocarry fragments or cuttings removed by the drill bit up the annulus andout of the well-bore. While the drilling fluid typically is pumpedthrough the inner annulus of the drill string and out of the drill bit,drilling fluid can be reverse-circulated. That is, the drilling fluidcan be pumped down the annulus (the space between the exterior of thedrill pipe and the wall of the well-bore) of the well-bore, across theface of the drill bit, and into the inner fluid channels of the drillbit through the jets or nozzles and up into the drill string.

Roller cone drill bits were the most common type of bit usedhistorically and featured two or more rotating cones with cuttingelements, or teeth, on each cone. Roller cone drill bits typically havea relatively short period of use as the cutting elements and supportbearings for the roller cones typically wear out and fail after only 50hours of drilling use. The teeth or cutting elements of roller cone bitstypically are formed of hard materials, such as steel and tungstencarbide. The action by which roller cone bits work is by applyingrelatively high force (weight-on-bit) so that the teeth gouge and crushthe rock formation.

Because of the relatively short life of roller cone bits, fixed cutterdrill bits that employ very durable polycrystalline diamond compact(PDC) cutters, tungsten carbide cutters, natural or synthetic diamond,other hard materials, or combinations thereof, have been developed.These bits are referred to as fixed cutter bits because they employcutting elements positioned on one or more fixed blades in selectedlocations or randomly distributed. Unlike roller cone bits that havecutting elements on a cone that rotates, in addition to the rotationimparted by a motor or drive, fixed cutter bits do not rotateindependently of the rotation imparted by the motor or drive mechanism.In contrast to roller cone bits that gouge or crush the formation, PDCcutters act by scraping or shearing the formation.

Through varying improvements, the durability of fixed cutter bits withplanar PCD elements and cutters has improved sufficiently to make themcost effective in terms of time saved during the drilling process whencompared to the higher, up-front cost to manufacture the fixed cutterbits.

PCD elements also may be used in various machine tools, such as planes,mills, drills, and lathes.

PCD elements also have been used as bearing surfaces in variousbearings, typically those that endure both rotational and thrust forces.PCD elements may be well suited because of their relatively lowercoefficient of friction and durability.

Despite many years of improvements, typical planar PCD elements maysuffer from chipping and spalling because of the high heat generated bythe shearing action. In addition, shearing may not always be the mostefficient mechanism by which to degrade various formations or workmaterials. In other words, the planar shape and shearing action may notbe able to provide a crushing or gouging action that might moreefficiently cut a formation or a work material.

Furthermore, with respect to bearings, the planar surface may not allowfor efficient cooling of the PCD element, leading to excessive heat thatcould lead to premature failure of the PCD element and, consequently thebearing.

Thus, there exists a need for a cost-effective and improved PCD elementfor use as a cutting element in downhole tools, machine tools, andbearing surfaces.

SUMMARY

Embodiments of a polycrystalline element include a table comprisingpolycrystalline diamond. For purposes of this application,polycrystalline diamond encompasses both cubic boron nitride (CBN),polycrystalline diamond (PCD), and other ultrahard materials compatiblefor use or as a substitute for CBN or PCD. Typically, these materialsare synthetic powders sintered at high-pressure and high-temperature toform a polycrystalline diamond compact or table as known in the art.

The table includes a first surface, typically a bearing surface or acutting surface, depending on the application. The table also includes asecond surface spaced apart from the first surface and at least one sideextending between the first surface and the second surface.

In addition, the polycrystalline element includes a plurality ofextensions comprising polycrystalline diamond, wherein at least oneextension of the plurality of extensions extends away from at least oneof the first surface and the at least one side.

Optionally, the polycrystalline element includes any one or more of thefollowing features in any combination. Stated differently, none of thefollowing features are mutually exclusive of other features, nor are anyof the following features required in any combination with any otherfeature or features.

At least one extension of the plurality of extensions may extend awayfrom the at least one side.

Optionally, the polycrystalline diamond of at least one extension of theplurality of extensions may be contiguous with the polycrystallinediamond of the table. In other words, the at least one extension may beformed of a piece or as an integral portion of the first surface.

Optionally, at least one extension of the plurality of extensions isspaced apart from at least one adjacent extension. A fluid flow path maybe defined by the space between the at least one extension and at leastanother extension. The fluid flow path may allow drilling fluid (whethera liquid or a gas, water-based, oil-based, or synthetic, lubricants, andother fluids) to cool, to lubricate, and to clean debris or cuttingsfrom the polycrystalline element.

At least a portion of the first surface may be one of spherical,hemi-spherical, cylindrical, planar, conical, frusto-conical, andpolyhedral in shape.

At least one extension of the plurality of extensions may include a longaxis that intersects at least one of the first surface and the side atan angle between 0 degrees to 90 degrees, 10 degrees to 80 degrees, 20degrees to 70 degrees, 30 degrees to 60 degrees, and 40 to 50 degrees,or any specific angle or subrange within these recited ranges. At leastone extension of the plurality of extensions may have a long axis thatintersects the first surface at an angle or a range of angles that isdifferent from the angle or the range of angles that at least anotherextension of the plurality of extensions intersects the first surface.The polycrystalline element optionally may further be defined by aradial line that extends radially outward from a center axis of thefirst surface that intersects each of the long axis of a subset of theplurality of extensions (As one of skill in the art would appreciate,this radial line does not exist in reality but is used to describe thephysical orientation and act as a landmark for the geographic discussionof the subset of the plurality of extensions.).

At least one extension of the plurality of extensions may include an endspaced apart from the first surface, wherein the end includes a curvedsurface.

Optionally, at least one extension of the plurality of extensionsincludes a first portion that is at least one of spherical,hemi-spherical, cylindrical, conical, frusto-conical, polyhedral,tear-dropped, and irregular shaped. The at least one extension of theplurality of extensions may also include a second portion positioned atan end of the first portion, wherein the second portion extends adistance away from the first surface. The second portion may be at leastone of spherical, hemi-spherical, cylindrical, conical, frusto-conical,polyhedral, tear-dropped, and irregular shaped.

At least one extension of the plurality of extensions may include aheight that is different from another height of at least anotherextension of the plurality of extensions. Similarly, each extension inat least a subset of the plurality of extensions includes a furthestmost point from the first surface, and wherein when the subset of theplurality of extensions is viewed in profile, a profile line intersectseach furthest most point of each extension within the subset of theplurality of extensions, and wherein the profile line intersects ahorizontal line coincident with the first surface.

The first surface may include at least one chamfered surface. Stateddifferently, the chamfered surface is part of, or a portion or subsetof, the first surface. In some instances, the first surface may includea plurality of chamfered surfaces. Optionally, at least one extension ofthe plurality of extensions extends away from the at least one chamferedsurface.

The polycrystalline element may further include a raised portioncomprising polycrystalline diamond that extends adjacent to at least afirst set of the plurality of extensions and a second set of theplurality of extensions. Optionally, the raised portion may bepositioned between all or one or more subsets of the plurality ofextensions. The polycrystalline diamond of the raised portion may becontiguous and/or integral with the polycrystalline diamond of the firstsurface. The raised portion may also include a raised portion surfacethat is at least one of planar, spherical, hemi-spherical, cylindrical,conical, frusto-conical, polyhedral, tear-dropped, and irregular shaped.

The polycrystalline element may further include at least one grooveextending at least partially into at least one of the first surface andthe at least one side.

The plurality of extensions may form various patterns. For example, theplurality of extensions may form a spiral pattern that begins with atleast one extension positioned closest to a center of the first surface,a concentric pattern around a center of the first surface, and others.At least a first subset of the plurality of extensions may be spacedapart from and parallel to at least a second subset of the plurality ofextensions.

The polycrystalline element may further include a substrate to which itis coupled to the second surface of the table. The substrate may, forexample, be a carbide substrate although other substrates may be used orno substrate at all may be used in those instances in which thepolycrystalline element stands alone or is coupled directly to anothercomponent, such as a drill bit, machine tool, or a bearing. Thus, thesubstrate may be an optional and non-essential part of thepolycrystalline element except as recited in the dependent claims. Thecarbide substrate may be bonded to the polycrystalline element via anyknown method, including pressing, brazing, sintering, adhering with avariety of adhesives, and other known methods. The second surface mayinclude any variety of locking and/or alignment features, slots, keys,crenellations, grooves, knobs, nodules, and other such features toengage with complementary features on the carbide substrate.

The polycrystalline element may be formed by a process that includes atleast one of laser machining, electro-discharge machining,electro-discharge grinding, and pressing (such as in a poly-axial pressand other methods of pressing) and other methods capable of forming thefeatures, preferably from an integral piece of polycrystalline diamondthat is used to form the table and at least one extension.

Further embodiments include a downhole tool that includes at least onepolycrystalline element incorporating one or more of the features asdescribed above. The downhole tool may be one of a roller cone bit, afixed blade bit, a bi-center drill bit, a hole opener, a reamer, and amill. Optionally, the various embodiments of the disclosedpolycrystalline elements may be a cutting element (primary and/or backupcutting element), wear resistant element (such as a gauge protectionfeatures or elements), stand-off elements, and the like.

A machine tool for use in at least one of a plane, a mill, a drill, anda lathe may include at least one polycrystalline element incorporatingone or more of the features as described above.

A bearing may include at least one polycrystalline element incorporatingone or more of the features as described above.

As used herein, “at least one,” “one or more,” and “and/or” areopen-ended expressions that are both conjunctive and disjunctive inoperation. For example, each of the expressions “at least one of A, Band C,” “at least one of A, B, or C,” “one or more of A, B, and C,” “oneor more of A, B, or C” and “A, B, and/or C” means A alone, B alone, Calone, A and B together, A and C together, B and C together, or A, B andC together.

Various embodiments of the present inventions are set forth in theattached figures and in the Detailed Description as provided herein andas embodied by the claims. It should be understood, however, that thisSummary does not contain all of the aspects and embodiments of the oneor more present inventions, is not meant to be limiting or restrictivein any manner, and that the invention(s) as disclosed herein is/are andwill be understood by those of ordinary skill in the art to encompassobvious improvements and modifications thereto.

Additional advantages of the present invention will become readilyapparent from the following discussion, particularly when taken togetherwith the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

To further clarify the above and other advantages and features of theone or more present inventions, reference to specific embodimentsthereof are illustrated in the appended drawings. The drawings depictonly typical embodiments and are therefore not to be consideredlimiting. One or more embodiments will be described and explained withadditional specificity and detail through the use of the accompanyingdrawings in which:

FIG. 1 discloses an example of a polycrystalline element as described inthe summary.

FIG. 2 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 3 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 4 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 5 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 6 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 7 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 8 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 9 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 10 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 11 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 12 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 13 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 14 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 15 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 16 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 17 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 18 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 19 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 20 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 21 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 22 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 23 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 24 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 25 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 26 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 27 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 28 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 29 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 30 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 31 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 32 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 33 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 34 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 35 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 36 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 37 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 38 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 39 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 40 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 41 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 42 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 43 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 44 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 45 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 46 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 47 is a cross-section view of the polycrystalline element in FIG.46 .

FIG. 48 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 49 is a cross-section view of the polycrystalline element in FIG.48 .

FIG. 50 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 51 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 52 discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 53A discloses another example of a polycrystalline element asdescribed in the summary.

FIG. 53B is a close-up view of the polycrystalline element in FIG. 53A.

FIG. 54 discloses a perspective view of a fixed blade drill bit that canbe used with any of the disclosed embodiments and examples of thepolycrystalline element.

FIG. 55A discloses a perspective view of a machine tool that can be usedwith any of the disclosed embodiments and examples of thepolycrystalline element.

FIG. 55B discloses a plan view of the machine tool in FIG. 55A.

FIG. 56 discloses a perspective view of an example of a bearing that canbe used with any of the disclosed embodiments and examples of thepolycrystalline element.

Common element numbers represent common features, even if the appearanceof a feature varies slightly between the figures.

The drawings are not necessarily to scale.

DETAILED DESCRIPTION

FIGS. 1-53A and 53B illustrate various views and examples of apolycrystalline element 100 as described more generally in the summaryabove. The polycrystalline element 100 may include any one or more ofthe following features in any combination as one of skill in the artwould understand, even if a particular combination is not specificallyrecited or illustrated. None of the features described below is mutuallyexclusive of another feature, nor is any feature described belowrequired to be in any combination with any other feature describedbelow. Stated yet differently, while many of the features will bedescribed with respect to FIG. 1 , any of those features described withrespect to FIG. 1 may be used with any of the other examples of thepolycrystalline elements 100 in any of the other figures, regardless ofwhether or not the feature is expressly recited in the relevant text orthe relevant figure. Likewise, any of the features described in any ofthe polycrystalline elements 100 in any of FIGS. 2-53A and 53B may beused with the polycrystalline element 100 in FIG. 1 , regardless ofwhether or not the feature is expressly recited in the relevant text orthe relevant drawing.

Embodiments of a polycrystalline element 100 include a table 101comprising polycrystalline diamond. For purposes of this application,polycrystalline diamond encompasses both cubic boron nitride (CBN),polycrystalline diamond (PCD), and other ultrahard materials compatiblefor use or as a substitute for CBN or PCD. Typically, these materialsare synthetic powders sintered at high-pressure and high-temperature toform a polycrystalline diamond compact or table as known in the art.

Referring to FIGS. 1-53A and 53B, the table 101 includes a first surface102, typically a bearing surface or a cutting surface, depending on theapplication as will be discussed below. The table 101 also includes asecond surface 103 spaced apart from the first surface 102 and at leastone side 104 extending between the first surface 102 and the secondsurface 103.

In addition, the polycrystalline element 101 includes a plurality ofextensions 110 comprising polycrystalline diamond, wherein at least oneextension 110A of the plurality of extensions 110 extends away from atleast one of the first surface 102 and the at least one side 103.Optionally, any number of the extensions, including all of the pluralityof extensions 110 may extend away from at least one of the first surface102 and the at least one side 103.

The polycrystalline diamond of at least one extension of the pluralityof extensions 110 is contiguous with and, optionally, formed integrallywith the polycrystalline diamond of the table 101.

At least one extension 110A of the plurality of extensions 110 may bespaced apart from at least one adjacent extension 110B, which optionallymay define a fluid flow path 212 therebetween to allow a fluid, such asdrilling fluid and/or lubricant to pass therethrough so as to provideone or more of cooling, lubricating, and cleaning of debris (e.g.,cuttings) from the area around the plurality of extensions 110 and thepolycrystalline element 100.

At least one extension 110A of the plurality of extensions 110 mayinclude a long axis 112 that intersects at least one of the firstsurface 102 and the at least one side 103 at an angle 114 between 0degrees to 90 degrees relative to the first surface and the side,respectively, as illustrated in at least FIG. 17 . Optionally, the angle114 may be within any subrange of 0 degrees to 90 degrees, such as 10degrees to 80 degrees, 20 degrees to 70 degrees, 30 degrees to 60degrees, and 40 to 50 degrees, or any specific angle or subrange withinthese recited ranges. At least one extension of the plurality ofextensions may have a long axis that intersects the first surface at anangle or a range of angles that is different from the angle or the rangeof angles that at least another extension of the plurality of extensionsintersects the first surface.

Optionally, and as illustrated in at least FIG. 1 , at least oneextension of the plurality of extensions 110 includes an end 116 spacedapart from the first surface 102, wherein the end 116 includes a curvedsurface 118.

At least one extension 110A of the plurality of extensions 110 mayinclude a first portion 120 that is at least one of spherical (e.g.,FIGS. 25, 37, and 42 ), hemi-spherical (e.g., FIGS. 2 and 9 ),cylindrical (e.g., FIG. 5 ), conical (e.g., FIGS. 15 and 19 ),frusto-conical (e.g., FIG. 32 ), polyhedral (e.g., FIG. 12 ),tear-dropped (e.g., FIG. 42 ), and irregular shaped (e.g., FIG. 41 ).

Optionally, the at least one extension 110A of the plurality ofextensions 110 includes a second portion 122 positioned at an end of thefirst portion 120, wherein the second portion 122 extends a distanceaway from the first surface 102 (e.g., FIG. 25 ). The second portion 122may be at least one of spherical, hemi-spherical, cylindrical (e.g.,FIG. 25 ), conical, frusto-conical, polyhedral (e.g., FIG. 8 ),tear-dropped, and irregular shaped.

Optionally, at least one extension 110A of the plurality of extensions100 includes a height 124A that is different from another height 124B ofat least another extension 110B of the plurality of extensions 110, asillustrated in, for example, FIG. 26 .

The first surface 102 may optionally include at least one chamferedsurface 105, as illustrated in at least FIGS. 4, 8, 13, 18, 31, 32 .Stated differently, the chamfered surface 105 is a part of or a portionof the first surface 102. The chamfered surface 105 may define a planethat intersects a horizontal plane, as one of skill in the art willunderstand from this description and the figures even without labelingthe various planes as such. Optionally, the first surface 102 mayinclude a plurality of chamfered surfaces, as illustrated in at leastFIGS. 18, 32, and 33 . At least one extension 110A of the plurality ofextensions 100 may extend away from the at least one chamfered surface105, as illustrated in at least FIGS. 4, 8, 31, and 32 .

Optionally, at least one extension 110A of the plurality of extensions100 may extend away from the at least one side 103, as illustrated in atleast FIG. 3 . The at least one extension 110 extending away from the atleast one side 103 may include a long axis (not labeled, although one ofskill of the art will understand the meaning in view of the discussionabove related to long axis 112) intersecting the at least one side 103at any angle between 0 degrees to 90 degrees or any sub-range orspecific angle between degrees to 90 degrees as discussed above relativeto the extensions extending away from at least the first surface 102.

The polycrystalline element 100 may include a raised portion 126comprising polycrystalline diamond that extends adjacent to at least afirst set of the plurality of extensions 111A and a second set of theplurality of extensions 111B, as illustrated in at least FIGS. 9-12, 18,47, and 49 . Optionally, the polycrystalline diamond of the raisedportion 126 may contiguous and optionally integrally formed with thepolycrystalline diamond of the first surface 102. The raised portion orat least a portion 126 may include raised portion surface 128 that is atleast one of planar (e.g., at least FIG. 9 ), spherical, hemi-spherical(e.g., at least FIG. 37 ), cylindrical, conical (e.g., at least FIG. 39), frusto-conical, polyhedral, tear-dropped, and irregular shaped.Stated differently, at least a portion 128 of the first surface 102 isone of spherical, hemi-spherical (e.g., at least FIG. 37 ), cylindrical,planar, conical (e.g., at least FIG. 39 ), frusto-conical, andpolyhedral.

As discussed above, for purposes of defining a geometric position of asubset of the plurality of extensions 110, a radial line 108 extendsradially outward from a center axis 107 of the first surface 102 andintersects each of the long axis 112 of a subset 113 of the plurality ofextensions 110, as illustrated in at least FIG. 4 .

Optionally, the plurality of extensions 110 may form a spiral pattern onthe first surface 102 that begins with at least one extension positionedclosest to a center or the center axis 107 of the first surface 102and/or a concentric pattern around a center or the center axis 107 ofthe first surface 102.

Optionally, at least a first subset 115A of the plurality of extensions110 is spaced apart from and parallel to at least a second subset 115Bof the plurality of extensions 110, as illustrated in at least FIG. 17 .

Optionally, the polycrystalline element 100 includes a carbide substrate200 coupled to the second surface 103 of the table 100. The carbidesubstrate may be of any type of carbide or other substitute for carbideto which polycrystalline diamond tables or compacts may be coupled to.The second surface 103 and the carbide substrate 200 may include variousthree-dimensional features that are complementary and/or interlock. Thesecond surface 103 may be adhered or pressed/sintered together to thecarbide substrate 200 in any manner typically used to do so as known inthe art.

Referring to FIGS. 50-52 , the polycrystalline element 100 may includeat least a subset 117 of the plurality of extensions 110, wherein eachextension in the the subset includes a furthest most point 119 from thefirst surface 102, and wherein when the subset 117 of the plurality ofextensions is viewed in profile, a profile line 130 intersects eachfurthest most point of each extension within the subset 117 of theplurality of extensions 110, and wherein the profile line intersects ahorizontal line 132 coincident with the first surface 102, asillustrated in at least FIG. 51 .

The polycrystalline element 100 may optionally include at least onegroove 109 extending at least partially into at least one of the firstsurface 102 and the at least one side 103, as illustrated in at leastFIGS. 46-49 . Within the at least one groove 109, at least anotherpolycrystalline extension 134 may be positioned and extend away from theat least one groove 103. The at least another polycrystalline extension134 may have any of the features described above with respect to thevarious polycrystalline extensions 110 and its various subsets in anycombination, as one of skill in the art would understand.

The polycrystalline element 100 in any of the various examples disclosedabove may be formed by a process that includes at least one of lasermachining, electro-discharge machining, electro-discharge grinding, andby pressing (e.g., any hydraulic press, including poly-axial presses).

Optionally, a downhole tool 300 may include at least one polycrystallineelement 100 in any variation as described above, as illustrated in FIG.54 . The downhole tool 300 may be one of a roller cone bit, a fixedblade bit (as illustrated in FIG. 54 ), a bi-center drill bit, a holeopener, a reamer, and a mill. As disclosed in FIG. 54 , the fixed bladebit 300 includes at least one blade 302, a junk slot or fluid flow path304, a connection 306 for coupling the bit 300 to a drill string or abottom hole assembly (not illustrated), and at least one jet to allowdrilling fluid to pass therethrough. The polycrystalline element 100 maybe brazed, press-fit, or otherwise coupled to the downhole tool, whetherdirectly to the surface or in a pocket configured to receive thepolycrystalline element 100.

Optionally, a machine tool 400 for use in at least one of a plane, amill, a drill, and a lathe, may use at least one polycrystalline element100 in any variation as described above, as illustrated in FIGS. 55A and55B. FIGS. 55A and 55B disclose a mill bit for use in a mill. Thepolycrystalline element 100 may be brazed, press-fit, or otherwisecoupled to the machine tool 400, whether directly to the surface or in apocket configured to receive the polycrystalline element 100.

Optionally, a bearing 500 may use at least one polycrystalline element100 in any variation as described above, as illustrated in FIG. 56 . Thebearing 500 as illustrated is a thrust bearing that includes a ring 502to which the polycrystalline element 100 is coupled. Of course, anyother type of bearing in any application may use at leastpolycrystalline element 100 in any variation as described above.

The one or more present inventions, in various embodiments, includescomponents, methods, processes, systems and/or apparatus substantiallyas depicted and described herein, including various embodiments,subcombinations, and subsets thereof. Those of skill in the art willunderstand how to make and use the present invention after understandingthe present disclosure.

The present invention, in various embodiments, includes providingdevices and processes in the absence of items not depicted and/ordescribed herein or in various embodiments hereof, including in theabsence of such items as may have been used in previous devices orprocesses, e.g., for improving performance, achieving ease and/orreducing cost of implementation.

The foregoing discussion of the invention has been presented forpurposes of illustration and description. The foregoing is not intendedto limit the invention to the form or forms disclosed herein. In theforegoing Detailed Description for example, various features of theinvention are grouped together in one or more embodiments for thepurpose of streamlining the disclosure. This method of disclosure is notto be interpreted as reflecting an intention that the claimed inventionrequires more features than are expressly recited in each claim. Rather,as the following claims reflect, inventive aspects lie in less than allfeatures of a single foregoing disclosed embodiment. Thus, the followingclaims are hereby incorporated into this Detailed Description, with eachclaim standing on its own as a separate preferred embodiment of theinvention.

Moreover, though the description of the invention has includeddescription of one or more embodiments and certain variations andmodifications, other variations and modifications are within the scopeof the invention, e.g., as may be within the skill and knowledge ofthose in the art, after understanding the present disclosure. It isintended to obtain rights which include alternative embodiments to theextent permitted, including alternate, interchangeable and/or equivalentstructures, functions, ranges or steps to those claimed, whether or notsuch alternate, interchangeable and/or equivalent structures, functions,ranges or steps are disclosed herein, and without intending to publiclydedicate any patentable subject matter.

LIST OF NUMBERED EMBODIMENTS

1. A polycrystalline element comprising:

-   -   a table comprising polycrystalline diamond, the table including:        -   a first surface;        -   a second surface spaced apart from the first surface;    -   at least one side extending between the first surface and the        second surface;

a plurality of extensions comprising polycrystalline diamond, wherein atleast one extension of the plurality of extensions extends away from atleast one of the first surface and the at least one side.

2. The polycrystalline element of claim 1, wherein at least oneextension of the plurality of extensions is spaced apart from at leastone adjacent extension.

3. The polycrystalline element of claim 1 or claim 2, wherein at leastone extension of the plurality of extensions includes a long axis thatintersects at least one of the first surface and the side at an anglebetween 0 degrees to 90 degrees relative to the first surface and theside, respectively.

4. The polycrystalline element of any of claims 1 through 3, wherein atleast one extension of the plurality of extensions includes an endspaced apart from the first surface, wherein the end includes a curvedsurface.

5. The polycrystalline element of any of claims 1 through 4, wherein atleast one extension of the plurality of extensions includes a firstportion that is at least one of spherical, hemi-spherical, cylindrical,conical, frusto-conical, polyhedral, tear-dropped, and irregular shaped.

6. The polycrystalline element of any of claims 1 through 5, wherein theat least one extension of the plurality of extensions includes a secondportion positioned between the first portion and the first surface,wherein the second portion extends a distance away from the firstsurface.

7. The polycrystalline element of claim 6, wherein the second portion isat least one of spherical, hemi-spherical, cylindrical, conical,frusto-conical, polyhedral, tear-dropped, and irregular shaped.

8. The polycrystalline element of any of claims 1 through 7, wherein atleast one extension of the plurality of extensions includes a heightthat is different from another height of at least another extension ofthe plurality of extensions.

9. The polycrystalline element of any of claims 1 through 8, wherein thefirst surface includes at least one chamfered surface.

The polycrystalline element of claim 9, wherein at least one extensionof the plurality of extensions extends away from the at least onechamfered surface.

11. The polycrystalline element of claim 9, wherein the first surfacecomprises a plurality of chamfered surfaces.

12. The polycrystalline element of any of claims 1 through 11, whereinat least one extension of the plurality of extensions extends away fromthe at least one side.

13. The polycrystalline element of any of claims 1 through 12, furtherincludes a raised portion comprising polycrystalline diamond thatextends adjacent to at least a first set of the plurality of extensionsand a second set of the plurality of extensions.

14. The polycrystalline element of claim 13, wherein the polycrystallinediamond of the raised portion is contiguous with the polycrystallinediamond of the first surface.

15. The polycrystalline element of claim 13, wherein the raised portionincludes a raised portion surface that is at least one of planar,spherical, hemi-spherical, cylindrical, conical, frusto-conical,polyhedral, tear-dropped, and irregular shaped.

16. The polycrystalline element of claim 3, wherein a radial lineextends radially outward from a center axis of the first surfaceintersects each of the long axis of a subset of the plurality ofextensions.

17. The polycrystalline element of any of claims 1 through 16, whereinthe plurality of extensions form a spiral pattern that begins with atleast one extension positioned closest to a center of the first surface.

18. The polycrystalline element of any of claims 1 through 17, whereinthe plurality of extensions form a concentric pattern around a center ofthe first surface.

19. The polycrystalline elements of any of claims 1 through 18, whereinat least a first subset of the plurality of extensions is spaced apartfrom and parallel to at least a second subset of the plurality ofextensions.

20. The polycrystalline element of any of claims 1 through 19, furthercomprising a carbide substrate coupled to the second surface of thetable.

21. The polycrystalline element of any of claims 1 through 20, whereinthe polycrystalline diamond of at least one extension of the pluralityof extensions is contiguous with the polycrystalline diamond of thetable.

22. The polycrystalline element of any of claims 1 through 21, whereinat least one extension of the plurality of extensions is spaced apartfrom at least another extension of the plurality of extensions so as todefine a fluid flow path therebetween.

23. The polycrystalline element of any of claims 1 through 22, whereinat least a portion of the first surface is one of spherical,hemi-spherical, cylindrical, planar, conical, frusto-conical, andpolyhedral.

24. The polycrystalline element of any of claims 1 through 23, whereineach extension in at least a subset of the plurality of extensionsincludes a furthest most point from the first surface, and wherein whenthe subset of the plurality of extensions is viewed in profile, aprofile line intersects each furthest most point of each extensionwithin the subset of the plurality of extensions, and wherein theprofile line intersects a horizontal line coincident with the firstsurface.

25. The polycrystalline element of any of claims 1 through 24, furthercomprising at least one groove extending at least partially into atleast one of the first surface and the at least one side.

26. The polycrystalline element of claim 25, wherein the at least onegroove includes at least another polycrystalline extension extendingaway from the at least one groove.

27. The polycrystalline element of any of claims 1 through 26, whereinthe polycrystalline element is formed by a process that includes atleast one of laser machining, electro-discharge machining,electro-discharge grinding, and by pressing.

28. A downhole tool that includes at least one polycrystalline elementof any of claims 1 through 27.

29. The downhole tool of claim 28, wherein the downhole tool is one of aroller cone bit, a fixed blade bit, a bi-center drill bit, a holeopener, a reamer, and a mill.

30. A machine tool for use in at least one of a plane, a mill, a drill,and a lathe, wherein the machine tool includes at least onepolycrystalline element of any of claims 1 through 27.

31. A bearing that includes at least one polycrystalline element of anyof claims 1 through 27.

1. A polycrystalline element comprising: a table comprisingpolycrystalline diamond, the table including: a first surface; a secondsurface spaced apart from the first surface; at least one side extendingbetween the first surface and the second surface; a plurality ofextensions comprising polycrystalline diamond, wherein at least oneextension of the plurality of extensions extends away from at least oneof the first surface and the at least one side, wherein the at least oneextension of the plurality of extensions includes a first portion thatis polyhedral shaped.
 2. The polycrystalline element of claim 1, whereinat least one extension of the plurality of extensions is spaced apartfrom at least one adjacent extension.
 3. The polycrystalline element ofclaim 1, wherein at least one extension of the plurality of extensionsincludes a long axis that intersects at least one of the first surfaceand the side at an angle between 0 degrees to 90 degrees relative to thefirst surface and the side, respectively.
 4. The polycrystalline elementof claim 1, wherein the at least one extension of the plurality ofextensions includes a second portion positioned between the firstportion and the first surface, wherein the second portion extends adistance away from the first surface.
 5. The polycrystalline element ofclaim 4, wherein the second portion is at least one of polyhedralshaped.
 6. The polycrystalline element of claim 1, wherein at least oneextension of the plurality of extensions includes a height that isdifferent from another height of at least another extension of theplurality of extensions.
 7. The polycrystalline element of claim 1,wherein the first surface includes at least one chamfered surface. 8.The polycrystalline element of claim 7, wherein at least one extensionof the plurality of extensions extends away from the at least onechamfered surface.
 9. The polycrystalline element of claim 1, wherein atleast one extension of the plurality of extensions extends away from theat least one side.
 10. The polycrystalline element of claim 1, furtherincludes a raised portion comprising polycrystalline diamond thatextends adjacent to at least a first set of the plurality of extensionsand a second set of the plurality of extensions.
 11. The polycrystallineelement of claim 10, wherein the polycrystalline diamond of the raisedportion is contiguous with the polycrystalline diamond of the firstsurface.
 12. The polycrystalline element of claim 10, wherein the raisedportion includes a raised portion surface that is at least one ofplanar, spherical, hemi-spherical, cylindrical, conical, frusto-conical,polyhedral, tear-dropped, and irregular shaped.
 13. The polycrystallineelement of claim 3, wherein a radial line extends radially outward froma center axis of the first surface intersects each of the long axis of asubset of the plurality of extensions.
 14. The polycrystalline elementof claim 1, wherein the plurality of extensions form a spiral patternthat begins with at least one extension positioned closest to a centerof the first surface.
 15. The polycrystalline element of claim 1,wherein the plurality of extensions form a concentric pattern around acenter of the first surface.
 16. The polycrystalline element of claim 1,further comprising a carbide substrate coupled to the second surface ofthe table.
 17. The polycrystalline element of claim 1, wherein thepolycrystalline diamond of at least one extension of the plurality ofextensions is contiguous with the polycrystalline diamond of the table.18. The polycrystalline element of claim 1, wherein at least oneextension of the plurality of extensions is spaced apart from at leastanother extension of the plurality of extensions so as to define a fluidflow path therebetween.
 19. The polycrystalline element of claim 1,wherein each extension in at least a subset of the plurality ofextensions includes a furthest most point from the first surface, andwherein when the subset of the plurality of extensions is viewed inprofile, a profile line intersects each furthest most point of eachextension within the subset of the plurality of extensions, and whereinthe profile line intersects a horizontal line coincident with the firstsurface.
 20. The polycrystalline element of claim 1, wherein thepolycrystalline element is formed by a process that includes at leastone of laser machining, electro-discharge machining, electro-dischargegrinding, and by pressing.
 21. A downhole tool that includes at leastone polycrystalline element in accordance with claim
 1. 22. The downholetool of claim 21, wherein the downhole tool is one of a roller cone bit,a fixed blade bit, a bi-center drill bit, a hole opener, a reamer, and amill.
 23. A machine tool for use in at least one of a plane, a mill, adrill, and a lathe, wherein the machine tool includes at least onepolycrystalline element in accordance with claim
 1. 24. A bearing thatincludes at least one polycrystalline element in accordance with claim1.